EP4326996A1 - Matériau façonné et son procédé de fabrication - Google Patents

Matériau façonné et son procédé de fabrication

Info

Publication number
EP4326996A1
EP4326996A1 EP22722559.6A EP22722559A EP4326996A1 EP 4326996 A1 EP4326996 A1 EP 4326996A1 EP 22722559 A EP22722559 A EP 22722559A EP 4326996 A1 EP4326996 A1 EP 4326996A1
Authority
EP
European Patent Office
Prior art keywords
shaped material
segments
radial
carbon fibers
disc
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22722559.6A
Other languages
German (de)
English (en)
Inventor
Omar CIVIDINI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Brembo SpA
Original Assignee
Brembo SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Brembo SpA filed Critical Brembo SpA
Publication of EP4326996A1 publication Critical patent/EP4326996A1/fr
Pending legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
    • F16D65/126—Discs; Drums for disc brakes characterised by the material used for the disc body the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • C04B35/573—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide obtained by reaction sintering or recrystallisation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62857—Coating fibres with non-oxide ceramics
    • C04B35/6286—Carbides
    • C04B35/62863—Silicon carbide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/121—Discs; Drums for disc brakes consisting of at least three circumferentially arranged segments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/128—Discs; Drums for disc brakes characterised by means for cooling
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/38—Non-oxide ceramic constituents or additives
    • C04B2235/3817—Carbides
    • C04B2235/3826—Silicon carbides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/428—Silicon
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
    • C04B2235/5248—Carbon, e.g. graphite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5264—Fibers characterised by the diameter of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/36—Non-oxidic
    • C04B2237/365—Silicon carbide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/38—Fiber or whisker reinforced
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/62—Forming laminates or joined articles comprising holes, channels or other types of openings
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/68—Forming laminates or joining articles wherein at least one substrate contains at least two different parts of macro-size, e.g. one ceramic substrate layer containing an embedded conductor or electrode
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/76—Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/1304—Structure
    • F16D2065/1312—Structure circumferentially segmented
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/1304—Structure
    • F16D2065/132—Structure layered
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/1304—Structure
    • F16D2065/1328—Structure internal cavities, e.g. cooling channels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0034—Materials; Production methods therefor non-metallic
    • F16D2200/0039—Ceramics
    • F16D2200/0047—Ceramic composite, e.g. C/C composite infiltrated with Si or B, or ceramic matrix infiltrated with metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0034—Materials; Production methods therefor non-metallic
    • F16D2200/0052—Carbon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/006—Materials; Production methods therefor containing fibres or particles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0023—Shaping by pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0038—Surface treatment

Definitions

  • the present invention relates to a shaped material and a method for manufacturing said shaped material.
  • said shaped material is a disc for disc brakes. More preferably, said shaped material is a ventilated disc for disc brakes.
  • discs for disc brakes made of carbon-based materials so-called “Carbon-Carbon” or “C/C” is known. These are composite materials consisting of a carbon matrix in which carbon reinforcing fibers are arranged.
  • carbon fibers or fibers made of a precursor of carbon
  • fibers are aggregated (alone or with the use of binding agents, for example resins) to form a three- dimensional structure called "preform".
  • binding agents for example resins
  • the most used carbon precursors are PAN, pitch and rayon.
  • the carbon matrix is obtained during densification processes of the fibrous structure, which may be performed in various manners, for example by means of Chemical Vapor Deposition (CVD), Chemical Vapor Infiltration (CVI), Liquid Polymer Infiltration (LPI), Polymer Infiltration and Pyrolysis (PIP), or impregnation with resin and/or pitch.
  • CVD Chemical Vapor Deposition
  • CVI Chemical Vapor Infiltration
  • LPI Liquid Polymer Infiltration
  • PIP Polymer Infiltration and Pyrolysis
  • impregnation with resin and/or pitch The discs made of "C/C” material are therefore obtained by means of a method that involves overlapping layers of fabric and/or non-woven fabric to form the so- called carbonaceous "preform", possible addition of resins, possible heat treatments, and carbon densification processes.
  • the latter lead to an increase in density such as to give the material adequate mechanical, thermal and tribological properties, for example a 2 to 6-fold increase in density.
  • the "C/C” material needs high application temperatures which make discs made of "C/C” material particularly suitable for applications in disc brakes intended to be installed on high-performance vehicles, for example, high-end cars or racing motorcycles .
  • discs for disc brakes comprise an annular portion, called braking band, intended to cooperate with brake pads of a caliper.
  • the braking band is made by means of two plates whose outer surfaces define opposite braking surfaces, while the inner surfaces delimit the portion of the disc comprising the ventilation holes for cooling the disc.
  • Said braking band is intended to cooperate with disc brake calipers, which are adapted to apply a braking action on the vehicle by applying, by means of the aforesaid pads friction on the opposite surfaces of the two plates, which are referred to as braking surfaces.
  • EP 3 308 053 describes a disc comprising a plurality of layers of carbon fibers, each of which, in turn, comprises a plurality of radial segments and transverse segments placed side by side, in which the number of transverse segments is greater than the number of radial segments. More in particular, within the aforesaid layers of carbon fibers, five radial segments are alternated with at least six or seven transverse segments.
  • the need is further particularly felt to reduce as much as possible the minimum thickness admissible for the disc plates, i.e., the admissible minimum thickness of the worn-out plates, i.e., consumed by the effect of the braking surfaces rubbing against the pad of a disc brake.
  • the disc architecture described in EP 3 308 053 requires a minimum thickness of the plates which - particularly in the highest-performance ranges of use - is desirable to reduce.
  • the problem underlying the present invention is to provide a shaped material, preferably a disc for disc brakes, which overcomes the drawbacks of the prior art, and a process for obtaining it which is convenient to implement. More specifically, the present invention aims at providing a shaped material capable of drastically reducing the possibility of cracks and fractures in a disc brake, while ensuring at the same time a high resistance of the disc and further reducing the minimum thickness admissible for the plates.
  • a first object of the invention is a shaped material having a circular or annular shape, for example, a disc for disc brakes, for example of ventilated type, comprising : a plurality of layers of carbon fibers stacked along an overlap axis Z, wherein each layer comprises a plurality of radial segments and transverse segments placed side by side and joined together to form said layer, wherein the radial segments are segments in which the carbon fibers are mainly oriented in a radial direction R relative to the overlap axis Z or oriented approximately parallel to the radial direction R, and the transverse segments are segments in which the carbon fibers are mainly oriented in a direction I incident to said radial direction
  • each radial segment is adjacent and joined, on both sides, to a transverse segment and each transverse segment is adjacent and joined, on both sides, to a radial segment, thus forming in each layer an alternation of radial segments and transverse segments.
  • a second object of the present invention is a method for manufacturing the shaped material as defined above, which comprises the following steps: a) stacking a plurality of layers of carbon fibers, or of precursors of said carbon fibers, along an overlap axis Z to form a multilayer body, each of said layers being formed by a plurality of radial segments and transverse segments, wherein each radial segment is adjacent and joined, on both sides, to a transverse segment and each transverse segment is adjacent and joined, on both sides, to a radial segment, forming in each layer an alternation of radial segments and transverse segments; b) subjecting the multilayer body obtained in step a) to a thermal or thermochemical densification treatment, so as to obtain said shaped material; c) optionally, infiltrating the shaped material obtained in step b) with an infiltrating agent, for example silicon (Si) or silicon carbide (SiC).
  • an infiltrating agent for example silicon (Si) or silicon carbide (SiC
  • the specific architecture of the layers of which the shaped material of the present invention is made i.e., the alternation of a radial segment and a transverse segment in each layer, gives the shaped material of the invention an increased flexural strength, as well as an increased drag resistance, compared to existing shaped materials made of "C/C" material which have different architectures of the layers.
  • the flexural strength of the disc plates is ensured with a number of layers in the plate which is lower than the known ventilated discs. This advantageously translates into a minimum thickness admissible for the worn-out plates which is less than that of the known ventilated discs.
  • the flexural strength of the ventilated disc is ensured with only three layers in the plate.
  • Figure 1 shows a perspective view of a fabrication step of the shaped material according to an embodiment of the invention.
  • Figures 2 and 3 diagrammatically show a radial segment and a transverse segment, respectively, usable in the shaped material of the present invention.
  • Figure 4 diagrammatically shows a side view of a disc for disc brakes of the ventilated type according to an embodiment of the invention.
  • Figure 5 diagrammatically shows the development over 360° of the architecture, so-called "1-1", of a shaped material according to an embodiment of the invention.
  • Figure 6 diagrammatically shows the development over 360° of the architecture, so-called "7-5", of a known shaped material, in which each layer has an alternation of seven transverse segments and five radial segments.
  • Figure 7 represents a chart showing the percentage of damaged volume vs. the torque (Nm) of a disc according to the present invention (“Disc 1-1”) and of a disc according to the prior art (“Disc 7-5").
  • a shaped material having a circular or annular shape comprising a plurality of layers of carbon fibers stacked along an overlap axis Z, also called construction axis Z, in which each layer is formed by a plurality of radial segments and transverse segments, and in which each radial segment is adjacent and joined, on both sides, to a transverse segment and each transverse segment is, in turn, adjacent and joined, on both sides, to a radial segment, forming in each layer an alternation of radial segments and transverse segments.
  • the shaped material according to the present invention relates to a disc for disc brakes, advantageously a disc of the ventilated type.
  • a first advantage linked to such feature concerns the possibility of increasing the thickness that can be worn out of the disc and consequently increasing the useful life of the disc itself, keeping unchanged the thickness of the plate at the beginning of the life cycle.
  • a further advantage linked to such feature concerns the possibility of reducing the thickness of the plate at the beginning of the life cycle of the disc, keeping unchanged the thickness that can be worn out, and therefore of increasing the number of ventilation holes and the thermal exchange of the disc by virtue of the greater space available for ventilation.
  • the disc according to the present invention is suited for use in braking systems of sports and high- performance cars.
  • the shaped material of the present invention is indicated, as a whole, with reference numeral 1.
  • the shaped material 1 comprises a plurality of layers 2, 3, 4, 5 of carbon fibers, such layers being stacked along an overlap axis Z, also called construction axis Z, for example shown vertically in Figure 1.
  • Figure 1 shows four layers 2, 3, 4, 5, but such number of layers is merely given by way of example and is not to be understood as limiting for the purposes of the present invention.
  • said overlap axis Z is oriented parallel to a rotation axis of the shaped material 1 or of the disc for disc brakes, during the use thereof.
  • Each layer 2, 3, 4, 5 comprises a plurality of segments 6, 7 placed side by side and joined together to form said layer, the segments of each layer 2, 3, 4, 5 comprising radial segments 6 and transverse segments 7.
  • the radial segments 6 are segments in which the carbon fibers are mainly oriented in a radial direction R relative to the overlap axis Z, or oriented approximately parallel to the radial direction R.
  • the transverse segments 7 are segments in which the carbon fibers are mainly oriented in a direction I incident to the radial direction R.
  • the diagrams of Figure 2 and Figure 3 show, respectively, the orientations of the carbon fibers in a radial direction and in a transverse direction on respective segments 6 and 7.
  • the incident direction I is substantially orthogonal with respect to the radial direction R.
  • At least one part of said segments 6, 7 is in the form of a circular sector or of a circular crown arch, as shown, for example, in Figure 1.
  • the circumferential width of said circular sectors or circular crown arches is comprised in the range 60-90°, preferably 60-80°, preferably 65-72°, for example about 68°.
  • all segments 6, 7 substantially have the same form.
  • all segments 6, 7 have the same circumferential width.
  • each segment mainly or exclusively comprises unidirectional carbon fibers, arranged in the radial direction R or in the incident direction I depending on whether it is a radial segment 6 or a transverse segment 7.
  • the segments of a layer 2 are angularly offset with respect to the segments of an adjoining layer 3 so that the joining zones 8 between the segments do not overlap through the thickness S of the shaped material 1.
  • each radial segment 6 of a layer 2 overlaps partly with a radial segment 6 and partly with a transverse segment 7 of an adjoining layer 3.
  • each radial segment 6 of a layer 2 overlaps with a radial segment 6 of an adjoining layer 3 for a portion equal to 5%-50%, preferably equal to 10%-40% or 15%-35%, of the circumferential width thereof, and with a transverse segment 7 of the adjoining layer 3 for a portion equal to 50%-95%, preferably equal to 60%-90% or 65%-85%.
  • each transverse segment 7 of a layer 2 overlaps partly with a transverse segment 7 and partly with a radial segment 6 of an adjoining layer 3.
  • each transverse segment 7 of a layer 2 overlaps with a transverse segment 7 of an adjoining layer 3 for a portion equal to 5%-50%, preferably equal to 10%-40% or 15%-35% of the circumferential width thereof, and with a radial segment
  • At least one segment of a layer 2 may be partially overlapped with at least one other segment that is alongside it in a circumferential direction.
  • each layer 2, 3, 4, 5 the number of radial segments 6 is equal to the number of transverse segments 7.
  • the segments 6, 7 extend in a spiral around the construction axis Z in a substantially continuous manner through the plurality of layers 2, 3, 4, 5 of carbon fibers.
  • the layers 2, 3, 4, 5 are represented by coils.
  • each coil has an inclination comprised in the range between 1° and 10°, preferably between 1° and 5°, for example of about 1°, relative to an axis orthogonal to the construction axis Z.
  • 5 of carbon fibers or coils is comprised in the range between 10 and 50, preferably between 18 and 40, for example between 20 and 35 or between 24 and 30. In a specific embodiment, the number of layers or coils is comprised between 21 and 26.
  • each of said layers 2, 3, 4, 5 of carbon fibers may have a thickness comprised between 0.5 mm and 3 mm, for example of about 1.25 mm or 1.5 mm .
  • the shaped material 1 may have a thickness S equal to or greater than about 5 millimeters, for example equal to or greater than about 25 millimeters, for example comprised between about 25 millimeters and about 300 millimeters, for example 28 millimeters, 32 millimeters, 38 millimeters or 40 millimeters.
  • At least one part of said carbon fibers are derived from oxidized polyacrylonitrile fibers.
  • said fibers are produced by the company SGL Carbon SE under the trade name Panox®.
  • the shaped material 1 comprises a carbonaceous matrix within which at least one part of said carbon fibers is incorporated.
  • carbonaceous matrix denotes a matrix composed by at least
  • the shaped material 50% of carbon.
  • silicon carbide (SiC) obtained by reaction of part of the carbon (C) of the carbon fibers and/or of the carbonaceous matrix of said shaped material 1 with at least part of silicon (Si) infiltrated in the shaped material 1.
  • said silicon carbide (SiC) is arranged as a bridge between layers 2, 3, 4, 5 of adjacent carbon fibers.
  • the shaped material 1 has a residual porosity of less than 5%, for example equal to or less than 3%.
  • the value of such residual porosity is considered for a shaped material 1 comprising silicon carbide (SiC) zones, specifically at the end of at least one step of infiltration with silicon (Si).
  • said shaped material 1 is a disc for disc brakes of the ventilated type, illustrated merely by way of example in Figure 4.
  • the ventilated disc in Figure 4 is indicated, as a whole, with the reference numeral 11.
  • Said ventilated disc comprises a first plate 12 and a second plate 13, which together constitute the so-called braking band.
  • Said first plate 12 is delimited by an outer surface 14 and an inner surface 15 and has a thickness y which extends between said two surfaces 14, 15.
  • said second plate 13 is delimited by an outer surface 16 and an inner surface 17 and has a thickness y which extends between said two surfaces 16, 17.
  • Said outer surfaces 14, 16 define opposite braking surfaces intended to cooperate with the pad of a disc brake. Said braking surfaces 14, 16 are subject to wear.
  • each plate 12, 13 is given by the sum of two dimensions represented by the "minimum thickness K" admissible for a plate and by the "thickness that can be worn out (y-K)".
  • minimum thickness K denotes the minimum thickness admissible for a worn-out plate, i.e., consumed by the effect of the braking surface rubbing against the pad of a disc brake, without the disc showing structural failures.
  • the "minimum thickness K” is the thickness of the worn-out plate at the end of the life cycle of the disc.
  • the “thickness that can be worn out (y-K)” is the thickness that is worn out, i.e., consumed, over time. The latter takes on a variable value. It is desirable that the "minimum thickness K" be as small as possible, so as to ensure a longer useful life of the ventilated disc.
  • the "minimum thickness K" of the plates 12, 13 of a disc 11 according to the present invention is formed by three of the aforesaid layers stacked along the overlap axis Z.
  • the flexural strength of the plates 12, 13 is ensured by the overlap of only three layers.
  • Figure 5 shows how the overlap of three layers allows to have, in each point along an axis orthogonal to the overlap axis Z, at least one transverse segment capable of giving the disc the desired flexural strength.
  • the flexural strength of the plates is ensured with a greater number of layers.
  • the flexural strength of the plates is ensured by the overlap of four layers. Therefore the "minimum thickness K" admissible for a plate of a disc with a "7- 5" architecture is necessarily greater.
  • a disc having a "1-1" architecture (Disc 1-1), in accordance with the present invention, is further provided with a greater mechanical strength with respect to a disc of the same geometry having a "7- 5" architecture (Disc 7-5).
  • the damaged volume of the Disc 1-1 is less than the damaged volume of the
  • preferred or accessory variants of such method may comprise any feature which may be deduced even only implicitly, from a structural point of view, from the above description.
  • Said method comprises the following steps: a) stacking a plurality of layers 2, 3, 4, 5 of carbon fibers, or of precursors of said carbon fibers, along an overlap axis Z to form a multilayer body, each of said layers being formed by a plurality of radial segments 6 and transverse segments 7, in which each radial segment 6 is adjacent and joined, on both sides, to a transverse segment 7 and each transverse segment 7 is, in turn, adjacent and joined, on both sides, to a radial segment 6, forming in each layer an alternation of radial segments 6 and transverse segments 7; b) subjecting the multilayer body obtained in step a) to a thermal or thermochemical densification treatment, so as to obtain the shaped material 1, 11; c) optionally, infiltrating the shaped material 1, 11 obtained in step b) with an infiltrating agent, for example silicon (Si) or silicon carbide (SiC).
  • said step a) also comprises a step of needling said stacked layers 2,
  • step a) comprises a step of arranging the segments 6, 7 in a spiral around the construction axis Z in a substantially continuous manner through the plurality of layers 2, 3, 4, 5 of carbon fibers.
  • said infiltrating agent comprises silicon (Si).
  • part of the infiltrated silicon (Si) reacts with part of the carbon (C) of the carbon fibers and/or of the carbonaceous matrix of the shaped material 1, 11 to form silicon carbide (SiC).
  • the needling step in step a) may comprise one or more steps of transposing, for example by means of shaped needles, the carbon fibers or the precursors of such carbon fibers through the thickness S of the different layers 2, 3, 4, 5 of the shaped material, forming an entangled three-dimensional structure.
  • the layers 2, 3, 4, 5 may comprise both carbon fibers (i.e., fibers already carbonized) or precursors of such fibers (for example, oxidized polyacrylonitrile fibers) which are transformed into carbon fibers during an optional carbonization step downstream of step a).
  • step b the densification treatment is carried out with different types of methods.
  • a first method is Chemical Vapor Deposition (CVD) or Chemical Vapor Infiltration (CVI), depending on whether there is only a coating or an infiltration of carbon in vapor form.
  • CVD Chemical Vapor Deposition
  • CVI Chemical Vapor Infiltration
  • These methods involve the use of hydrocarbon mixtures (for example, methane and propane) and the exposure of the material to be treated to such mixtures at high temperatures and low pressures. Operating temperatures are in the range of 900-1200°C, preferably 1000-1100°C, and pressures below 300 mbar are used, preferably of a few tens of mbar.
  • the hydrocarbon mixtures decompose to form elemental carbon, which is then deposited or infiltrated into the matrix of the material being treated.
  • This method which requires the use of dedicated furnaces, involves the deposition of a thin layer (typically a few microns) on the fibers; therefore, several cycles of infiltration and overall coatings on the fibers higher than ten microns (typically 10-20 microns) are required in order to obtain the desired densification.
  • LPI Infiltration
  • PIP Polymer Infiltration and Pyrolysis
  • LPI liquid polymer
  • pyrolysis high-temperature heat treatment
  • Such method is performed by immersing one or more preforms in a liquid polymer bath inside an autoclave.
  • the infiltration step is carried out at a pressure comprised between 50 and 500 mbar and at a temperature comprised between 20 and 50°C, preferably at room temperature.
  • the preform is left immersed for a time preferably comprised between 10 and 120 minutes, for example between 15 and 45 minutes.
  • the polymer is cured at a temperature which is a function of the material used.
  • the material is pyrolyzed in an inert environment at a temperature preferably comprised between 700 and 1000°C, for example comprised between 850°C and 950°C, to convert the polymeric matrix into carbon. Also in this case, several steps of infiltration and pyrolysis are required before appropriate densification of the preform is achieved. The entire process is typically repeated a minimum of three times until the desired density is reached.
  • silicon is infiltrated into the shaped material by means of a liquid silicon infiltration (LSI) process, during which the silicon is brought to a temperature higher than the melting temperature thereof so as to melt and infiltrate by capillarity into said shaped material.
  • LSI liquid silicon infiltration
  • the shaped material is placed on a layer or bed of silicon, preferably powdered, for example, by means of porous septa, such as felts, elements of pyrolyzed wood or pegs.
  • Said treatment chamber is introduced into a suitable furnace of the conventional type, which is heated to a temperature preferably above 1410°C, more preferably comprised between 1420°C and 1700°C, for example, at about 1500°C. At these temperatures the silicon melts, rises by capillarity inside the pores of the shaped material and at least partially reacts with part of the carbon of the carbon fibers and/or of the carbonaceous matrix to form silicon carbide (SiC).
  • a suitable furnace of the conventional type which is heated to a temperature preferably above 1410°C, more preferably comprised between 1420°C and 1700°C, for example, at about 1500°C.
  • the silicon melts, rises by capillarity inside the pores of the shaped material and at least partially reacts with part of the carbon of the carbon fibers and/or of the carbonaceous matrix to form silicon carbide (SiC).
  • Both the heating to the treatment temperature and the subsequent cooling are conducted gradually. For example, it can take up to 8 or more hours to reach a temperature of treatment of about 1500°C and a similar amount of time to cool the infiltrated pad.
  • said silicon infiltration process is conducted at a reduced pressure comprised between 20 mbar and 150 mbar, more preferably between 80 mbar and 120 mbar.
  • the process and the shaped material of the present invention may be implemented with great simplicity in any existing production line, above all by virtue of the relative constructive simplicity.
  • the process and the shaped material of the present invention allow to achieve considerable manufacturing savings, by virtue of the fact that specific processes do not require supplementary or additional machinery with respect to those usually provided.
  • a person skilled in the art could make variations or replacements of elements with other equivalent operations.
  • Such variants are also included in the scope of protection as defined by the following claims.
  • each variant described as belonging to a possible embodiment may be implemented independently from the other described variants.

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Abstract

La présente invention concerne un matériau façonné (1, 11), par exemple, un disque pour freins à disque, et son procédé de fabrication. Plus particulièrement, l'invention concerne un matériau façonné comprenant une pluralité de couches (2, 3, 4, 5) de fibres de carbone empilées le long d'un axe de chevauchement (Z), chaque couche (2, 3, 4, 5) étant formée par une pluralité de segments radiaux (6) et de segments transversaux (7), chaque segment radial (6) étant adjacent et relié, des deux côtés, à un segment transversal (7) et chaque segment transversal (7) étant adjacent et relié, des deux côtés, à un segment radial (6), formant dans chaque couche (2, 3, 4, 5) une alternance de segments radiaux (6) et de segments transversaux (7).
EP22722559.6A 2021-04-19 2022-04-14 Matériau façonné et son procédé de fabrication Pending EP4326996A1 (fr)

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IT102021000009803A IT202100009803A1 (it) 2021-04-19 2021-04-19 Materiale sagomato e relativo metodo di produzione
PCT/IB2022/053507 WO2022224095A1 (fr) 2021-04-19 2022-04-14 Matériau façonné et son procédé de fabrication

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US5546880A (en) * 1994-12-29 1996-08-20 The Bf Goodrich Company Annular filamentary structures and methods of making
ATE259763T1 (de) * 1999-11-25 2004-03-15 Dunlop Aerospace Ltd Abriebsbeständige gegenstände
KR20050020986A (ko) * 2002-06-11 2005-03-04 슝크 코렌슈토프테크닉 게엠베하 Ｔｆｐ 공정에 따라 제조된 마찰 특성을 가진 섬유복합재료 부품
CA2957709A1 (fr) * 2014-08-08 2016-02-11 Advanced Carbon Technologies, Llc Preformes de rotor de frein non tissees a reduction de fracture et plaquettes
US11215250B2 (en) 2015-06-10 2022-01-04 Freni Brembo S.P.A. Shaped material and manufacturing method

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IT202100009803A1 (it) 2022-10-19

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